Shoe insole element

ABSTRACT

A shoe insole element includes an upper portion and a lower portion, the upper portion having a plurality of upper projections and a plurality of voids located alongside the upper projections. The lower portion includes a plurality of lower projections which extend into the voids to resist flexing of the upper projections toward one another under the action of a wearer&#39;s foot. The lower portion can be made selectively separable from the upper portion by the wearer to release the resistance to such flexing, or the lower portion can be permanently bonded to the upper portion. The stiffness of the upper and lower projections can be mutually different. The insole element can be configured for use in different regions of a shoe, such as the heel and/or arch regions, or it can constitute the entire insole.

BACKGROUND

The present invention relates to shoe insoles and in particular to shoe insole elements that can be inserted into a shoe to augment one or more portions of the insole, or even constitute the entire insole.

Shoe insoles have been designed in various forms in order to provide a cushioning action for the wearer's foot. For example, an insole, or parts of an insole, can be formed of a combination of materials having different respective degrees of stiffness. The materials are typically fixedly joined together, e.g., by adhesive or by embedding one material within another. For example, Published U.S. Application No. 2007/0022630 discloses an insole in which an upper gel layer thereof is formed of a stiffer material than a lower gel layer on which it is situated. The underside of the lower layer forms a series of downward spring walls shaped in various patterns.

In U.S. Pat. No. 6,460,275 there is disclosed an orthotic device used in the heel portion of an insole. The device comprises an upper cup portion formed of a soft silicone material seated on a stiffer wedge portion. The cup portion includes an even more flexible blind bore portion arranged to overlie a cutout in the wedge portion. The blind bore portion is able to be pushed into the cutout by the heel of the wearer to cushion the heel and disperse the heel-strike forces. Although the upper cup portion is removable from the wedge portion, those portions are designed only to be used together, not separately.

It would be desirable to provide an improved way of cushioning a wearer's sole.

It would also be desirable to provide a way of cushioning a wearer's sole in a manner that is adjustable.

It would further be desirable to provide a way of cushioning a wearer's sole in such manner that the degree of cushioning can be adjusted by the wearer.

SUMMARY

A shoe insole element comprises an upper portion and a lower portion, the upper portion having upper projections and voids located alongside the upper projections. The lower portion includes lower projections which extend into the voids to resist flexing of the upper projections toward one another under the action of a wearer's foot.

In one aspect of the invention, the lower portion is selectively separable from the upper portion to release the resistance to such flexing. In that event, the upper and lower portions can be of the same or different stiffness.

In another aspect of the invention, the upper and lower portions are not selectively separable from one another, in which case the upper projections are of different stiffness (i.e., more or less stiff) than the lower projections.

The insole element can be configured for use in specific regions of the shoe such as the heel region and/or the arch region for example. Separate insole elements for the respective regions could be provided, or a one-piece insole element covering multiple regions or the entire shoe insole could be provided.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and advantages of the invention will become apparent from the following detailed description of preferred embodiments thereof in connection with the accompanying drawings in which like numerals designate like elements and in which:

FIG. 1 is a bottom plan view of a heel insert including a lower portion installed in an upper portion.

FIG. 2 is a side elevational view of FIG. 1.

FIG. 3 is a sectional view taken along line 3-3 in FIG. 1.

FIG. 4 is a bottom plan view of the upper portion of the heel insert with the lower portion removed.

FIG. 5 is a top plan view of the lower portion of the heel insert.

FIG. 6 is a bottom plan view of FIG. 5.

FIG. 7 is a top plan view of the heel insert.

FIG. 8 is a sectional view taken along the line 8-8 in FIG. 7.

FIG. 9 is an inverted exploded perspective view of the heel insert showing the lower portion separate from the upper portion.

FIG. 10 is a perspective view of a shoe broken away to show the heel insert seated therein.

FIG. 11 is a bottom plan view of an arch insert with a lower portion thereof installed in an upper portion.

FIG. 12 is a side elevational view of FIG. 11, it being understood that the arch insert is upside-down with respect to its in-use position in a shoe.

FIG. 13 is a cross-sectional view taken along line 13-13 in FIG. 11.

FIG. 14 is a bottom plan view of the upper portion of the arch insert without the lower portion installed therein.

FIG. 15 is a top plan view of the lower portion of the arch insert.

FIG. 16 is an exploded perspective view showing how the bottom section of the arch insert installs into the upper portion.

FIG. 17 is a perspective view of a shoe broken away to show the arch insert installed therein.

FIG. 18 is a perspective view of a shoe broken away to depict a heel insole element attached integrally to an arch insole and inserted into the insole, or forming an integral part of the shoe insole.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

Illustrated in the accompanying figures are a heel insert 10 (FIGS. 1-9) and a shoe carrying the heel insert (FIG. 10), plus an arch insert 50 (FIGS. 11-16) and a shoe carrying the arch insert 100 (FIG. 17). The heel and arch inserts have a common feature, namely each is comprised of upper and lower portions. The upper portion has projections (called upper projections) spaced apart by voids. The lower portion has projections (called lower projections) which extend into the voids to affect the ability of the upper projections to flex toward one another. In one embodiment, the lower portion is selectively removable from the upper portion at the discretion of the wearer so that the upper projections are freely flexible toward one another in the absence of the lower projections, or less flexible in the presence of the lower projections to a degree dependent on whether the lower projections are of greater, lesser or equal stiffness as the upper projections.

In another embodiment, the lower portion is not selectively removable, so the degree of flexibility of the upper projections depends on whether the lower projections are stiffer or less stiff than the upper projections.

Depicted in FIGS. 1-9 is an insole element in the form of a heel insert 10 adapted to be inserted onto the heel region of a shoe insole. The insert 10 comprises upper and lower portions 12, 14 (shown in upside-down relationship in FIG. 9). The insert's upper portion 12 forms an upwardly open cup 13 at a rear end of its upper surface 20 for receiving a wearer's heel, the cup shape defined by a base 16 and an upstanding rear wall 18 (see FIG. 3). The upper portion 12 also includes a lower surface 22 adapted to mate with the lower portion 14. The lower surface 22 includes a rear region 24 having formed therein a series of voids 28 arranged in an arc and forming therebetween a series of rib-like projections 26 also arranged in an arc. The voids extend into the rear wall so that the projections 26 include horizontal segments 30 and vertical segments 32. In the region of the lower surface 22 bordered by the rear wall 18, i.e., beneath the cup of the upper portion 12, there is formed a series of concentric annular voids 34 which form therebetween a series of concentric annular projections 36. The voids 34 become progressively vertically deeper toward the center C of the arch (see FIG. 3), so the projections 36 become progressively vertically longer toward the center of the arch.

The insert's lower portion 14 is shaped to mate with the projections/voids 26, 28 and with the projections/voids 36, 34. Thus, the lower portion includes a center section 39 from which extend a series of finger-like projection 40 arranged in an arc along an outer periphery of the center section 39. Each projection 40 includes a horizontal segment 42 and a vertical segment 44. The projections 40 are separated by voids 46 and are arranged to be received in the voids 28 of the upper portion 12, and the projections 26 of the upper portion are arranged to be received in the voids 46 of the lower portion to resist flexing of the projections 26 under the action of a user's foot.

Extending from a top surface of the center section 39 are concentric annular rib-like projections 45 separated by concentric annular voids 47. The projections 45 are arranged to be received in respective voids 34 of the upper part 12 in order to resist flexing of the projections 34 toward one another under the action of a wearer's foot.

In one aspect of the invention, the lower portion 14 is selectively removable from the upper portion, whereby the heel insert 10 can be used with or without the lower portion 14. Without the lower portion 14, the upper portion is more flexible in the rear region thereof. That is, by removing the lower portion 14 from the upper portion 12 before inserting the heel insert 10 into the heel of the shoe 48 (see FIG. 10), the resistance to flexing of the upper projections is released, because the projections 26 of the upper portion are free to flex toward one another (i.e., flex into the adjacent voids 28), and the projections 36 are likewise free to flex toward one another, in response to the action of the wearer's foot, thereby increasing the flexibility and cushioning action of the insole element 10. The flexing of the projections 36 can occur generally radially with respect to the common center C of the projections 36, i.e., laterally and/or longitudinally of the shoe. Some of the projections 26, i.e. located at the back of the wall 18 can flex laterally of the shoe, whereas others of the projections 26, i.e. those located along the sides of the wall 18 can flex longitudinally of the shoe.

If the user elects to assemble the lower portion 14 with the upper portion, then the ability of the upper projections to flex toward and away from one another will be resisted by the lower projections, the degree of resistance being dependent upon the stiffness of the lower projections. In that regard, the lower projections can have a greater, a lesser, or the same stiffness as the upper projections.

In practice, the wearer would determine whether to utilize both of the upper and lower portions 12, 14 of the heel insert 10, to provide a stiffer cushioning action, or to utilize only the upper portion 12 to provide a more flexible cushioning action.

If only the upper portion 12 is to be utilized, the user removes the lower portion 14 prior to inserting the heel insert into the shoe. If desired, the heel insert can be removed from the shoe in order to mount the lower portion into the upper portion to provide a stiffer cushioning action when returned to the shoe. It is required that the heel insert be outside of the shoe in order for the lower portion to be removed or installed.

In another aspect of the invention, the lower portion 14 is not removable from the upper portion 12, i.e., the lower portion is permanently bonded to the upper portion 12, in any suitable manner, e.g., by adhesive or a chemical bond created by molding one portion to the other In that event, the flexibility of the upper projections will be dependent on the amount of the difference in stiffness between the upper and lower projections.

The upper and lower portions 12, 14 can be formed of any suitable materials, most preferably a visoelastic polymer or silicone gel which is highly energy absorbent. Preferred materials include, but are not limited to, thermoplastic elastomers including styrene-olefin-rubber block copolymers, ethylene copolymers, thermoplastic polyolefins, thermoplastic polyurethanes, polyamides, polyureas, polyesters, thermoplastic rubbers, natural rubbers, nylon, ethylvinyl acetate and other materials whose softness is a function of temperature.

Depicted in FIGS. 11-17 is another preferred embodiment, i.e., an insole element shaped as an arch insert 50 suitable for use in the arch region of a shoe. That insert 50 includes an upper portion 52 and a lower portion 54. The upper portion 52, which has a somewhat rectangular shape as viewed in plan (FIG. 11), includes two edges 55, 56 extending in a front-to-rear longitudinal direction (corresponding to the front-to-rear direction of the shoe in which the element is to be inserted), with one of the edges 56 being curved such that a forward portion of the arch insert 50 flares outwardly to form a wide front end 58 and a narrow rear end 60. The vertical thickness of the arch insert 40 gradually increases in a lateral direction with respect to the longitudinal direction, i.e., the thickness increases from the edge 55 to the edge 56, in order to conform to the shape of the arch of a wearer's foot (see FIG. 13). The upper portion 52 includes upper and lower surfaces 64, 66 with the lower surface 66 having formed therein a plurality of upper projections 68 separated by downwardly open voids 70. The projections and voids 68, 70 are generally linear and parallel and extend laterally from a location adjacent the edge 56 to a location adjacent the edge 55. The plurality of projections 68 and voids 70 is surrounded by a flat border 73 which is intended to rest on the insole of a shoe 48.

The lower portion 54 includes rib-like lower projections 72 spaced apart by upwardly open voids 74. The projections 72 are linear and parallel and are arranged on a flat base portion 75. The projections 72 are arranged to extend into the voids 70 of the upper portion in order to prevent the upper projections 68 from flexing toward one another (i.e., from flexing into the voids 70). As in the case of the first embodiment, the lower portion 54 can be selectively removable from, or permanently bonded to, the upper portion 52. If selectively removable, then by removing the lower portion 54 from the upper portion 52 before inserting the arch insert 50 into the shoe, the projections 68 would be able to flex freely toward one another in response to forces applied by the wearer, the flexing occurring in the generally front-to-rear (longitudinal) direction of the shoe.

If the lower portion 54 is assembled with the upper portion 52, the ability of the upper projections 68 to flex is resisted, depending on the amount of difference in flexibility between the upper and lower projections. The lower projections 72 can be of greater, lesser or equal stiffness relative to the upper projections 68.

If the lower portion 54 is permanently bonded to the upper portion 52, then the degree of flexibility depends upon the amount of the difference in flexibility between the upper and lower projections.

When the lower portion 54 is inserted into the upper portion, a bottom surface 77 of the lower portion lies flush with the border 73 of the upper portion 52.

The upper and lower portions 52, 54 can be formed of the same materials described earlier in connection with the heel insert.

Although the heel and arch inserts 10, 50 have been described thus far as separate units, it will be appreciated that they could be combined into a single integral unit 100 for insertion into the heel/arch region of the shoe as shown in FIG. 18, or as part of a one-piece shoe insole that could replace an existing shoe insole and which would also appear as shown in FIG. 8.

Although the present invention has been described in connection with preferred embodiments thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departing from the spirit and scope of the invention as defined in the appended claims. For example, the projections and voids shown in the preferred embodiments could be shaped or oriented differently or disposed at different locations than the ones shown. 

1. A shoe insole element comprising an upper portion and a lower portion, the upper portion having a plurality of upper projections and a plurality of upper voids located alongside the upper projections, the lower portion including a plurality of lower projections which extend into the upper voids to resist flexing of the upper projections toward one another under the action of a wearer's foot.
 2. The insole element according to claim 1 wherein the lower portion is selectively separable from the upper portion to release the resistance to flexing of the upper projections.
 3. The insole element according to claim 2 wherein the upper projections include projections stiffer than lower projections.
 4. The insole element according to claim 2 wherein the upper projections include projections less stiff than lower projections.
 5. The insole element according to claim 2 wherein the upper and lower projections are of equal stiffness.
 6. The insole element according to claim 1 wherein the lower portion is permanently bonded to the upper portion.
 7. The insole element according to claim 6 wherein the upper projections include projections stiffer than lower projections.
 8. The insole element according to claim 6 wherein the upper projections include projections less stiff than lower projections.
 9. The insole element according to claim 1 wherein the upper portion comprises a viscoelastic polymer.
 10. The insole element according to claim 1 wherein the upper portion comprises a silicone gel.
 11. The insole element according to claim 1 configured for use at least in a shoe's heel region, wherein the upper portion includes a base and a rear wall upstanding from a rear end of the base, at least some of the upper projections disposed on a bottom side of the base.
 12. The insole element according to claim 11 wherein some of the upper projections are disposed on the rear wall.
 13. The insole element according to claim 12 wherein the upper projections disposed on the bottom surface of the base comprise generally concentric circular ribs spaced apart by generally concentric circular voids.
 14. The insole element according to claim 13 wherein the upper projections disposed on the rear surface of the back wall is arranged in an arc.
 15. The insole element according to claim 1 configured for use at least in a shoe's arch region, each of the upper and lower portions including a front end and a rear end spaced apart in a front-to-rear longitudinal direction of the element, the rear end being narrower than the front end, the upper portion being of gradually increasing thickness in a direction laterally of the longitudinal direction, the upper and lower projections extending laterally of the longitudinal direction.
 16. The insole element according to claim 15 wherein the plurality of upper projections is surrounded by a flat border of a bottom surface of the upper portion.
 17. The insole element according to claim 15 wherein the upper projections are parallel to the upper voids.
 18. A shoe insole defining at least a heel region and an arch region, each of the heel region and the arch region comprising an upper portion and a lower portion, the upper portion having a plurality of upper projections and a plurality of voids located alongside the upper projections, the lower portion including a plurality of lower projections which extend into the voids to resist flexing of the upper projections toward one another under the action of a wearer's foot.
 19. The shoe insole according to claim 18 wherein the lower portion is selectively separable from the upper portion to release the resistance to flexing of the upper projections.
 20. The shoe insole according to claim 18 wherein the upper projections include projections stiffer than lower projections.
 21. The shoe insole according to claim 18 wherein the upper projections include projections less stiff than lower projections. 